The present invention relates generally to valve assemblies as are typically provided on fluid supply lines to enable fluid flow to be regulated. The invention relates more particularly to a safety valve assembly which can be connected between inlet and outlet pipework to enable electrical isolation therebetween.

Fluids are typically delivered to buildings using an interconnected pipework system comprising a network of mains supply lines. Such fluids are generally supplied at one or more central sources and are pumped through the pipework system at high pressure to ensure that fluid is transmitted across the entire network.

Fluid pipework must be robust to resist the high pressures exerted by fluid being pumped therethrough and also to resist damage caused by weathering and general wear and tear. Fluid pipework is typically, therefore, composed of high strength, durable materials, such as metals. Many metals are conductive and this presents a risk that fluid contained within metal pipework may be exposed to an electrical connection. When pipework is used to transport flammable and/or explosive fluids, such as natural gas, there is a risk that an electrical charge could ignite the fluid, thus triggering a fire and/or explosion.

Regulatory building safety measures often require that pipework is electrically isolated from the mains network by an electrical isolation system fitted to each building. This ensures that, should an electrical contact be made with the pipework provided within a building, then electrical current is not transmitted to the entire mains network.

Prior art electrical isolation systems provide a pipework fitting composed of electrically insulating material (typically plastic) which is provided between the mains supply line and the building pipework. Typically, such a fitting is located adjacent to other safety measures, such as an emergency control valve (ECV). Building regulations require that an ECV is installed on gas pipework in residential buildings so that fluid flowing to the building can be "shut-off" in case of emergency.

Prior art systems are, however, not optimal. Plastic pipework is susceptible to fire damage, and hence could result in a significant gas leak following a fire. Also, since such prior art systems utilise an additional pipework fitting, this is not optimal from the perspective of space and cost. Furthermore, there is the potential for the fitting to be omitted during pipework installation. Other prior art electrical isolation systems utilise an integrated solution in which the ECV itself is provided with an electrical isolation means. In such systems, the ECV is made up of a stack of parts having an inlet portion which is electrically isolated from an outlet portion by an intermediate non-conducting barrier, such as a non-conducting washer. Such prior art systems are, however, susceptible to bending loads. Such bending loads might be encountered during building collapse following a fire, might be applied to the valve assembly during installation, or might occur due to expansion/contraction (e.g. due to thermal expansion) of components of the valve assembly or adjoining pipework. Bending loads can cause the electrically isolated portions of the system to come into contact with one another and thereby create an electrical connection therebetween. Additionally, prior art systems often utilise intermediate non-conducting barriers composed of materials which are susceptible to fire damage (such as plastics). If a fire were to damage or destroy such a plastic barrier then its ability to isolate the inlet portion and outlet portion would be compromised.

It is therefore an object of the invention to obviate or mitigate the abovementioned disadvantages and to provide an improved safety valve assembly.

According to the present invention there is provided a safety valve assembly for connection to a fluid supply line, comprising:

i) a valve unit, having a first end and a second end defining an axis therebetween, said valve unit comprising a valve between said first and second ends; and

ii) a connection fitting for fluidly connecting the first end of the valve unit to the fluid supply line, the connection fitting comprising:

a) a first tubular member fittable to, or integral, with the first end of the valve unit,

b) a second tubular member adapted for receiving the fluid supply line, and c) a pair of washers locatable between said first and second tubular members so as to maintain the first tubular member in a non- contacting arrangement relative to the second tubular member to restrict relative movement therebetween;

wherein one of the first and second tubular members is locatable within the other tubular member, each washer in the pair of washers is positionable in an axially spaced relationship relative to the other washer, and wherein each washer is composed of electrically insulating, thermally resistant material, thereby enabling electrical isolation of the first and second tubular members from one another.

The valve assembly of the present invention is particularly suited for use with pipework supplying gaseous fluids, such as natural gas which is supplied to residential buildings for heating and cooking purposes. For the purposes of clarity in the remainder of the description, the present invention will be described in the context of natural gas supplied to residential buildings. As will be appreciated, however, the safety valve assembly of the present invention has application to other fluids, such as liquids, particularly flammable and/or explosive liquids, such as petroleum. Equally, the safety valve assembly of the present invention has application for use with pipework supplying non-residential buildings, such as commercial buildings or even pipework for supplying gas externally of buildings. The skilled person will readily understand the applicability of this invention to other such applications and the remaining description should not be construed as being limited only to applications utilising natural gas in residential buildings. The valve assembly of the present invention provides a number of advantages over prior art assemblies as set out more fully below. The valve assembly provides an integrated system by which gas pipework within residential buildings can be shut off from the mains supply in case of emergency, while also ensuring that the building pipework is electrically isolated from the mains supply. Having such an integrated system ensures that, since a gas shut off must be installed when installing residential pipework (due to building safety regulations), there is no risk that the electrical isolation system will not also be installed. The assembly of the present invention thus provides a compact, single piece solution for providing a shut off from the mains supply in case of emergency which also electrically isolates residential pipework from the mains. The spaced relationship of the pair of washers gives the assembly resistance to mechanical bending loads. Such loads might be encountered during building collapse following a fire, might be applied to the valve assembly during installation, or might occur due to expansion/contraction (e.g. due to thermal expansion) of components of the valve assembly or adjoining pipework. The spaced relationship of the washers ensures that bending loads applied to the assembly are spread across both washers. This mitigates point loading problems which might be encountered with a system employing a single washer alone and thus mitigates the risk of electrically isolated portions coming into contact with each other.

The valve assembly of the present invention has a further advantage that, in the event of a fire, the thermally resistant washers resist fire damage so as to ensure that the electrical isolation is maintained. For the avoidance of doubt, the term "pair of washers" does not preclude the presence of a greater number (odd or even) of washers. The valve assembly of the present invention may comprise three washers, four washers, five washers, or more, depending on the application. Additionally, the term "within" as used to define the relationship between the first and second tubular members is not necessarily to be interpreted as meaning completely within. The valve assembly of the present invention may have a tubular member which is located only partially within the other tubular member, or may have a tubular member which is located completely within the other tubular member. The valve unit, the first tubular member and/or the second tubular member may be constructed of metal. The metal may be steel, copper, brass, aluminium or iron, as are conventional materials used in gas pipework. In certain embodiments these parts should be capable of withstanding temperatures of about 820 °C, as is typically encountered during a normal fire test.

The second tubular member may have a threaded internal bore for connection to a threaded gas supply line. The internal bore may be tapered to improve the seal of the connection with the supply line. The valve assembly may be arranged so that the first tubular member surrounds the second. Alternatively the valve assembly may be arranged so that the second tubular member surrounds the first. The valve assembly provides a fluid connection between an inlet gas supply line and gas pipework for a residential building. The assembly should provide a hermetically sealed connection to avoid a gas leak of fluid flowing therethrough. Suitably, the assembly may comprise sealing gaskets, such as O-rings, so as to improve the hermetic seal of the assembly. Such gaskets might be placed, for example, between the washers and the tubular member(s) and/or in the valve unit.

The first and/or second tubular members may be engageable with one or both of the washers in the pair to restrict relative axial movement of the respective tubular member(s) within the connection fitting. Such an engagement provides resistance against the first and second tubular members becoming dislodged from another, which could otherwise result in a substantial gas leak. The first and/or second tubular members may be provided in a clamping relationship with one or both washers in the pair. The first and/or second tubular members may be provided in an abutting relationship with one or both washers in the pair. Suitably, the first tubular member comprises a first retaining lip and/or the second tubular member comprises a second retaining lip, one or both washers in the pair being provided therebetween. The lip may take the form of a recess, flange, groove, etc.

One or both washers in the pair may be stepped washers having an inner and/or outer circumferential flange.

The electrically insulating, thermally resistant material may be a ceramic material. The ceramic material is preferably selected from the group consisting of sintered boron nitride and alumina.

The assembly may further comprise a third tubular member locatable in the spacing between the pair of washers, the third tubular member being composed of an electrically insulating material, such as plastic. Suitable plastic materials include those having high strength and toughness grades, and which also have high dielectric strength, such as engineering plastics including polyoxymethylene (acetal). Such a third tubular member can be shaped to provide rotational resistance to the connection fitting as described more fully below.

The first, second and third tubular members may be configured so that relative rotation therebetween is restricted or prevented. Thus, for example, the first, second and third tubular members may have complementary adjacent facing surfaces which either contact each other or are in closely spaced relationship and which are configured for restricting or preventing relative rotation. These surfaces may be polygonal (e.g. octagonal) as seen transverse to the longitudinal axis of the respective member. In such an embodiment, the first tubular member may be rotatably fixed relative to the second and third tubular members. In this instance, the connection fitting is able to resist rotational movement applied when installing a fluid supply line into the second tubular member. In particular, rotational movement of the second tubular member is resisted by the fact that its outer surface contacts with the inner surface of the third tubular member, which in turn is prevented from rotation by virtue of contact of its outer surface with the inner surface of the first tubular member.

Having tubular members shaped and arranged in this manner allows the assembly to resist rotational loads (such as might be applied when a fluid supply line is connected to the second tubular member via a threaded engagement) by cooperating abutment of the facing surfaces of each of the tubular members.

The first tubular member may be snap- or screw-fittable onto the valve unit for ease of connection.

The first, second and or third tubular members may be formed of two or more pieces. The pieces may be connectable together using snap-fit connections, screw-fit connections or the like. The aforementioned features described in connection with each of the respective tubular members may, where appropriate, relate to one or more of the pieces. In embodiments where the first tubular member is formed of two pieces, for example, the first piece may be integral with the valve unit while the second piece may be separable from the valve unit. In such an example the second piece may be fittable (e.g. snap fittable or screw fittable) onto the first piece. In embodiments where screw-fit connections are used, thread-locking adhesive may be provided in the connection to restrict movement further.

For a better understanding, the present invention will now be more particularly described, by way of non-limiting example only, with reference to and as shown in the accompany schematic drawings (not to scale) in which:

Fig. 1 is a schematic side sectional view of a first embodiment of a safety valve assembly in accordance with the invention;

Fig. 2 is the same schematic side sectional view of the embodiment of the safety valve assembly shown in Fig. 1 ;

Fig. 3 is an end view of the connection fitting of the safety valve assembly shown in Figs. 1 and 2, with certain parts cut away;

Fig. 4 is a schematic side sectional view of the outer nut of the safety valve assembly shown in Figs. 1 -3; Fig. 5 is a schematic side sectional view of a second embodiment of a safety valve assembly in accordance with the invention;

Fig. 6 is a schematic perspective view of a kit of parts for the connection fitting of the safety valve assembly shown in Fig. 5; and

Fig. 7 is a schematic side sectional view of a third embodiment of a safety valve assembly in accordance with the invention.

Figs. 1 and 2 illustrate a first embodiment of a safety valve assembly 1 in accordance with the invention comprising a valve unit 3 for regulating fluid flow and a connection fitting 5 for fluidly connecting the valve unit 3 to a fluid supply line (not illustrated). The connection fitting 5 of the safety valve assembly 1 shown in Figs. 1 and 2 is also shown in Fig. 3, which illustrates a partially cutaway end view of the connection fitting 5 as seen in the direction of arrow X (Fig. 1 ). The valve unit 3 comprises a metal housing 7 having an inlet end 9 and an outlet end 1 1 which define an axis 13 therebetween. A valve 15 is provided between the inlet 9 and outlet 1 1 ends of the valve unit 3. The connection fitting 5 is comprised of a stack of parts, described in more detail below, configured so as to electrically isolate an inlet fluid supply line from the valve unit 3 and thereby outlet pipework (not illustrated) connected thereto.

The connection fitting 5 comprises a first tubular member 17, which is a two piece metal construction comprising a first tubular piece 17a (hereafter "integral tube"), having inner 19 and outer 21 surfaces, integral with the metal housing 7 of the valve unit 3, and a second piece in the form of an outer tubular nut 17b, having inner 23 and outer 25 surfaces, which is screw fit onto the outer surface 21 of integral tube 17a. The outer tubular nut 17b of the connection fitting 5 shown in Figs. 1 -3 is also shown in Fig. 4. Outer tubular nut 17b and integral tube 17a are adhered together using a thread- locking adhesive to restrict separation by relative rotation. Together, the integral tube 17a and the outer nut 17b define a tubular passageway connected to the inlet end 9 of the valve unit 3. The internal diameter of the integral tube 17a is smaller than that of the outer nut 17b, as described in greater detail below.

The connection fitting 5 further comprises a second tubular member in the form of a tubular metal insert 27, having inner 29 and outer 31 surfaces, located coaxially and completely within the outer nut 17b. The insert 27 has a threaded tapered internal bore (tapering not shown) for connection to a fluid supply line and has a similar internal diameter to that of the integral tube 17a.

The first tubular member 17 and the insert 27 are maintained in non-contacting relationship with, and electrically isolated from, one another by means of a pair of ceramic washers 33, 35. Washers 33, 35 are coaxial with and located between the first tubular member 17 and the insert 27 so as to maintain the first tubular member 17 and the insert 27 in said non-contacting arrangement relative to one another. The washer 33 is located axially between the integral tube 17a and the insert 27. The washer 35 is in an axially spaced relationship relative to the washer 33 and is located radially between the outer nut 17b and the insert 27. The location and composition of the washers 33, 35 ensures that the first tubular member 17 and the insert 27 are electrically isolated from one another. In addition, the axially spaced relationship of the washers 33, 35 gives the assembly 1 resistance to mechanical bending loads. The washers 33, 35 are each engaged with both the first tubular member 17 and the insert 27 so as to restrict movement within the connection fitting 5. The engagement with each of the washers 33, 35 is provided by cooperating abutments 37, 39, 41 , 43 formed on surfaces of the first tubular member 17 and the insert 27 as explained more fully below.

The washer 33 is engaged with the integral tube 17a of the first tubular member 17 and the insert 27. This engagement is made by means of abutments in the form of first 37 and second 39 circumferential recesses, as indicated by dashed lines. The first 37 and second 39 circumferential recesses are provided on internal surfaces 19 and 29 of the integral tube 17a and the insert 27 respectively. The first circumferential recess 37 is provided on the inner surface 19 of integral tube 17a at an end thereof which is distal to valve unit 3. A second circumferential recess 39 is provided on the inner surface 29 of the insert 27 adjacent an end thereof which is proximate the valve unit 3. The washer 33 is located with a portion in each of the first 37 and second 39 circumferential recesses and axially between the integral tube 17a and insert 27 and abuts against each of the integral tube 17a and the insert 27.

The washer 35 is engaged with the outer nut 17b of the first tubular member 17 and the insert 27. This engagement is made by means of a third circumferential recess 41 , as indicated by dashed lines, provided on the outer surface 31 of the insert 27 and a flange 43 extending inwardly from the inner surface 23 of the outer nut 17b. The third recess 41 is provided on the insert 27 at an end thereof which is distal to the inlet end 9 of the valve unit 3. The flange 43 extends from an end of the outer nut 17b which is distal to the inlet end 9 of the valve unit 3. The washer 35 abuts against each of the third circumferential recess 41 , the flange 43 and the inner surface 23 of outer nut 17b.

As shown in greater detail in Fig. 2, which only has certain features labelled for clarity, the outer radial diameters di _, d ₂ of the first 37 and second 39 circumferential recesses respectively are substantially the same as an outer radial diameter d ₃ of the washer 33, so as to form a close fit therebetween. The sum of the axial widths w ₂ of the first 37 and second 39 recesses respectively is less than the axial width w ₃ of the washer 33 located therebetween. This maintains that the integral tube 17a and the insert 27 in an axially spaced relationship to one another (i.e. they do not touch) so as to ensure electrical isolation therebetween. The washer 35 has an inner diameter d ₄ which is substantially the same as an inner radial diameter d ₅ of the third recess 41 so as to form a close fit therebetween. The washer 35 has an outer diameter d ₆ which is substantially the same as an inner diameter d ₇ of the outer nut 17b, similarly resulting in a close fit therebetween. The outer diameter d ₆ of the washer 35 is greater that the radial diameter d ₅ of the third circumferential recess 41 . This maintains that outer nut 17b and the insert 27 in a radially spaced relationship to one another (i.e. do they not touch) so as to ensure electrical isolation therebetween.

The relationships between the diameters of the circumferential recesses 37, 39, 41 ; the outer nut 17b; and the washers 33, 35 facilitate assembly while also ensuring that the parts remain concentric once assembled. Referring again to Fig. 1 , the arrangement of the washers 33, 35 defines a circumferential spacing between the first tubular member 17 and insert 27. A third tubular member 45, having inner 47 and outer 49 surfaces, is provided in the circumferential spacing. The third tubular member 45 is composed of plastic and thus does not compromise the electrical isolation between the first 17 and second 27 tubular members.

As can be best appreciated from Fig. 3, the outer surface 31 of the insert 27 and the inner 47 and outer 49 surfaces of the third tubular member 45 are of octagonal transverse cross-section. As is best shown in Fig. 4, the outer nut 17b has an inner surface 23 which has a first portion 23a of circular cross section and second portion 23b of octagonal cross section. When assembled, the outer nut 17b is rotatably fixed relative to the insert 27 and third tubular member 45.

The outer nut 17b, the third tubular member 45 and the insert 27 are in a nested arrangement. Insert 27 has an octagonal outer surface 31 which nests concentrically within, and in contact with, the octagonal inner surface 47 of third tubular member 45. Similarly, the third tubular member 45 has an octagonal outer surface 49 which nests concentrically within, and in contact with, the second octagonal portion 23b of the inner surface 23 of the outer nut 17b. The outer surface 31 of the insert 27 and the inner surface 47 of the third tubular member 49 are, therefore, mutually complementary so that the former surface is in contact with the latter. Similarly, the outer surface 49 of the third tubular member 45 and the second octagonal portion 23b of inner surface 23 the outer nut 17b are mutually complementary so that the former surface is in contact with the latter surface. Although, in this embodiment, the aforementioned surfaces are in contact with one another, they could equally be in closely spaced relationship with one another.

The arrangement is such that the connection fitting 5 is able to resist rotational movement applied when installing a fluid supply line (not shown) into the insert 27. In particular, rotational movement of the insert 27 is resisted by the fact that its octagonal outer surface 31 is in contact with the octagonal inner surface 47 of the third tubular member 45 which in turn is prevented from rotation by virtue of the contact of its octagonal outer surface 49 with the octagonal inner surface portion 23b of the outer nut 17b, the latter being non-rotatably fixed to the integral tube 17a.

The valve assembly 1 further comprises O-rings 51 and 53 disposed around the washer 33 so as to improve the hermetic seal of the assembly 1 .

Fig. 5 shows a second embodiment of a safety valve assembly 1 ' in accordance with the invention. A kit of parts for the connection fitting of the safety valve assembly 1 ' of Fig. 5 is shown in Fig. 6. The assembly of the second embodiment is similar to the first embodiment shown in Figs. 1 to 4 and only the differences between the two assemblies will be described in detail below. In Figs. 5 and 6 the components corresponding to those described above in relation to Figs. 1 to 4 take the same reference number but suffixed with a prime symbol ( ' ).

As with the first embodiment shown in Figs. 1 to 4, the first tubular member 17' and the insert 27' of the safety valve assembly 1 ' of Fig. 5 are maintained in non-contacting relationship with, and electrically isolated from, one another by means of a pair of axially spaced ceramic washers 33', 35'. The non-contacting relationship differs from that in Figs. 1 to4 as explained more fully below.

The washer 33' is located within outer nut 17b' and axially between integral tube 17a' and the insert 27'. The inner diameter d ₇ of the outer nut 17b' is the same as the outer diameter d ₈ of the washer 33' so as to form a close fit therebetween. A circumferential flange 33a' is provided around the outer circumference of the washer 33' and extends towards the end of the outer nut 17b' which is distal from the valve unit 3'. The circumferential flange 33a' surrounds a complementarily shaped circumferential lip 27a' provided around the outer surface 31 ' of the insert 27'. Thus, the outer nut 17b' and the insert 27' are separated from one another in a non-contacting relationship by means of the circumferential flange 33a' located therebetween.

As best shown Fig. 6, a second portion 23b' of an inner surface 23' of the outer nut 17b' , the outer surface 31 ' of the insert 27' and the inner 47' and outer 49' surfaces of the third tubular member 45' are of octagonal polygonal cross-section. When assembled, the outer nut 17b' is rotatably fixed relative to the insert 27' and third tubular member 45'.

As with the first embodiment discussed in relation to Figs. 1 to 4 above, the outer nut 17b', the third tubular member 45' and the insert 27' are in a nested arrangement such that the connection fitting 5' is able to resist rotational movement applied when installing a fluid supply line (not shown) into the insert 27'.

In the event of a fire, the plastic third tubular member 45, 45' and O-rings 51 and 53 may be destroyed. The ceramic (i.e. thermally resistant) washers 33, 33', 35, 35' are, however, maintained, such that the electrical isolation remains intact.

When installing the valve assembly 1 , 1 ', a fluid supply line is screwed into the threaded internal bore of the insert 27, 27'. The connection fitting 5, 5' resists the rotational movement applied while screwing in said fluid supply line due to the nested arrangement resulting in contact of complementary facing surfaces of each of the first tubular member 17, 17', the insert 27, 27' and the third tubular member 45, 45'. In particular, rotational movement of the insert 27, 27' is resisted by the fact that its octagonal outer surface 31 , 31 ' is in contact with the octagonal inner surface 47, 47' of the third tubular member 45, 45' which in turn is prevented from rotation by virtue of the contact of its octagonal outer surface 49, 49' with the octagonal inner surface portion 23b, 23b' (see Fig. 6 for 23b') of the outer nut 17b, 17b' the latter being non-rotatably fixed to the integral tube 17a, 17a'. Fig. 7 shows a third embodiment of a safety valve assembly 1 " in accordance with the invention. The assembly of the third embodiment is similar to those shown in Figs. 1 to 6 and only the substantive differences between the assemblies will be described in detail below. In Fig. 7, the components corresponding to those described above in relation to Figs. 1 to 6 take the same reference number but suffixed with a double prime symbol ( " ).

As with the assemblies shown in Figs. 1 to 6, the safety valve assembly 1 " in accordance with the third embodiment of the invention comprises a valve unit 3" having a valve 15", and a connection fitting 5". The connection fitting 5" differs from that shown in Figs. 1 to 6 as explained more fully below.

The connection fitting 5" comprises a first tubular member 17", which is a single piece metal construction integral with the metal housing 7" of the valve unit 3". The connection fitting 5" further comprises a second tubular member in the form of a tubular metal sleeve 55. Sleeve 55 is a two-part construction comprising a first portion 55a located coaxially around the first tubular member 17" and a second portion 55b screw-fit into an inner surface of first portion 55a. The second portion 55b of sleeve 55 has a threaded internal bore for connection to fluid supply line (not illustrated).

As with the assemblies shown in Figs. 1 to 6, the arrangement of the washers 33", 35" defines a circumferential spacing between the first tubular member 17" and sleeve 55. A third tubular member 45" is provided in the circumferential spacing. In addition, the axially spaced relationship of the washers 33", 35" gives the assembly 1 " resistance to mechanical bending loads.

The inner surface 47" of the third tubular member 45" is of octagonal cross-section. Similarly, parts of the outer surface 21 " of the first tubular member 17", and of the outer surface 57 of the second portion 55b of the sleeve 55, which face the inner surface 47" of the third tubular member 45", are of complementary octagonal cross-section. The connection fitting 5" resists rotational movement applied while screwing in said fluid supply line through contact of these facing surfaces 47", 21 ", 57 in a similar manner to that discussed above in relation to the assemblies shown in Figs. 1 to 6.